Collator with stapling means and storage means



Oct. 27, 1970 C. W. GAY ETAL COLLATOR WITH STAPLING MEANS AND STORAGE MEANS Filed Feb. 15, .1968

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COLLATOR WITH STAPLING MEANS AND STORAGE MEANS Filed Feb. 15, 1968 5 Sheets-Sheet 5 ouwor waves-om \smm1o H596 Twsseems WQVEFORM 1 5 M 0R Tm" Rem VM on w vj a M w T WH VEFORMS POSWE VOLTRGE FFD DI CHRHHGE DROP l INVENTORS \V u r 06 w 6 W o TY Qu hh H O DAM) Q W A 0 United States Patent 3,536,318 COLLATOR WITH STAPLING MEANS AND STORAGE MEANS Charles Warren Gay, 1023 Wertland St., Charlottesville,

Va. 22903, and Arthur J. Hepler, In, Charlottesville, Va.; said Hepler assignor to said Gay Filed Feb. 15, 1968, Ser. No. 705,830

Int. Cl. B6511 39/02 US. Cl. 270-58 11 Claims ABSTRACT OF THE DISCLOSURE This invention is directed to a collating machine for the assembling of sets of sheets of paper or the like in a chosen order. The machine of this invention utilizes a plurality of trays for holding the paper and a plurality of sets of rollers for ejecting the paper. This machine also provides for the assembly of sets of the papers and thereafter for stapling the papers together before permitting the sets of papers to be accumulated in a storage bin.

This invention relates to a collating machine or gatherer used in the collating or assembling of sets of sheets of paper or the like in a chosen order. The particular collating machine of this invention is constructed to dispense single sheets from a plurality of trays or bins, such that they are collected in a predetermined order to form a set.

This invention also provides for aligning the sheets after they are assembled into a set and, additionally, if desired, provides means for fastening the set together before expelling the set into a collecting container.

As another important feature, this invention provides means for ejecting a set of papers which was not properly assembled.

The collating machine of this invention is capable of performing the above completely automatically after all the trays are filled and the machine is turned on. The machine will continue operating automatically until all the papers are assembled or until one of the trays has been emptied of sheets of paper. The machine will automatically shut off if a sheet of paper becomes hung up in the guide means positioned between the trays and the support means for collecting the papers into a set.

In view of the foregoing, it is an object of this invention to provide a new and improved collating machine.

Another object of this invention is to provide a new and improved collating machine which will automatically assemble sheets of paper into a set and thereafter fasten the sheets together.

A further object of this invention is to provide a new and improved collating machine which utilizes a paper ejecting mechanism constructed to dispense one sheet from each tray during each machine cycle.

Still other objects and advantages of the invention will in part be obvious and will in part be apparent from the specification.

The invention accordingly comprises the features of construction, combinations of elements and arrangements of parts which will be exemplified in the constructions hereinafter set forth and the scope of the invention will be indicated in the claims.

For a fuller understanding of the nature and objects of the invention reference is had to the following description taken in connection with the accompanying drawings, in which:

FIG. 1 is a perspective view of the collating machine of this invention;

FIG. 2 is another perspective view from a different aspect of the collating machine of this invention;

Patented Oct. 27, 1970 FIG. 3 is a sectional view taken along line 33 of FIG. 1;

FIG. 4 is a sectional view taken along line 4-4 of FIG. 2;

FIG. 5 is a sectional view taken along line 5-5 of FIG. 4;

FIG. 6 is a sectional view taken along line 66 of FIG. 3;

FIG. 7 is a sectional view taken along line 7-7 of FIG. 3;

FIG. 8 is a. view taken along line 8-8 of FIG. 3;

FIG. 9 is a view taken along line 99 of FIG. 3;

FIG. 10 is a top view showing a group of papers assembled in a set with fastening means holding the set together;

FIG. 11 is a block diagram of a control system for operating the collating machine according to this invention;

FIG. 12 is a circuit diagram illustrating a silicon rectifier control circuit used in FIG. 11; and

FIG. 13 is a timing chart of signal waveforms provided from various circuits shown in FIG. 11.

Referring now to FIG. 1, there is shown a perspective view of the collating machine of this invention, having a base 10 supporting a cabinet or frame 11 on which there is mounted a plurality of trays shown at 12 for holding paper to be dispensed. A control box for operating the machine is generally shown at 13 and a basket 14 is provided for receiving the set of papers after it has been released from the collating machine. At 15 are shown switches for bypassing a particular tray in the event papers are not placed within that tray.

FIG. 2. shows a view of the collating machine from the opposite side. At 18 are shown guide means comprising guide rods for guiding the paper held within the trays 12 to a bin generally shown at 19. In the base of the bin 19 there is provided a sliding door or plate 20 to retain the set of papers within the bin. At 21 there is provided an aligning mechanism or jogging mechanism for aligning the papers while held within the bin 19. While the papers are held within the bin 19, fastening means, such as a stapler 22, may be utilized to fasten all the papers together in a single set. Thereafter, the plate 20 is moved and the set of papers is permitted to fall into the basket 14.

Referring now to FIGS. 3, 4 and 5, there is shown the position of the trays 12 and the guide rods 18. The guide rods are constructed such that the paper held in the lowest tray will first enter the bin 19 and be followed by papers held in successively higher-positioned trays. As shown, the bin 19 comprises the outer wall of the cabinet 11, particularly shown at 24, and a sloped portion shown at 25. As mentioned previously, a plate 20 is provided which is slidable in the direction shown by the arrow and pulled in that direction by actuation of a solenoid assembly shown at 26. Normally, the plate is retained by a spring 27, such that it closes the opening at the bottom of bin 19. In order to dispense the papers from the trays 12, there is provided a plurality of rubber rollers which are coupled to rods shown at 31 supported in a frame member shown at 32. The rods 31 are driven through a bevel gear arrangement 34 by a shaft 35 which, in turn, is driven by a motor 36 mounted on the frame. The drive shaft for the motor is shown at 37, which is coupled through a slidable coupling 38 to the shaft 35. As constructed, the frame 32 is movable in the direction of the arrow 39. This is accomplished by the provision of a solenoid assembly 40 mounted on a support member 41 coupled to the frame. A spring member 44 is provided to take the load off the system, that is, permit the use of a small solenoid assembly to raise the frame or carriage 32. Whenever the rollers 30 are in contact with the papers, they will dispense the papers onto the guide rails 18 such that the papers dispensed will accumulate into a set in the bin 19. When the rollers are raised, new paper can be inserted in the trays.

As another feature of this invention, at 46 a movable plate is provided which acts as reject means and is capable of moving in front of and under the bin 19 so as to catch a set of papers in the event a paper has not been sensed as being ejected from each of the trays 12. The plate 46 is pivoted at 47 and is moved by actuation of a solenoid assembly shown at 48. The plate 46 is normally held in an up and out-of-the-way position by a spring shown at 49.

FIG. 3 also shows the photo-electric sensing system, comprising a light source 51 for directing a beam of light 52 toward a photo-electric sensor shown at 53. The light 52 will intercept any papers held or caught on the guide rods 18. As may be seen in FIG. 6, the guide rods comprise two for each tray, spaced apart in such a manner that the light beam may pass between the two rods for each tray. In the event a paper is caught on the guide rods, the sensor 53 will detect that the light is not present and will cause the machine cycle to stop so that an operator may clear the machine. In FIG. 3 there is also shown microswitch feelers 56, one for each tray, which sense if there is paper held within each tray. In the event there is no longer any paper in the trays, or in one of the trays, the machine cycle will cease and the tray or trays can then be refilled.

With reference now to FIG. 6, there is shown a front view of the trays having raised corner pieces 57 for preventing the paper from slipping out and also to retain the bottom sheet as the top sheet is dispensed therefrom by the rollers.

As an additional feature of this invention, there is pro vided a microswitch sensor 58, including feeler means for each tray. The purpose of the switch 58 is to sense that a piece of paper has been dispensed from each tray. In the event a paper leaving the tray is not sensed, it will cause the ejecting plate 46 to intercept the set of papers and, accordingly, the set will be ejected into the reject container 59 (-FIG. 3).

Referring now to FIGS. 3, 7 and 8, there are shown two plates 60 and 61 having pads of foam latex or the like which act to hold the sheets of paper in place and prevent their moving while they are held in the tray. The plates 60 and 61 are hinged to members 63 and 64, respectively, and are controlled by two rods 66 and 67, respectively, pivotally supported under one tray at 68. The plates 60 and 61 are also connected to the rods 66 and 67, respectively, by rigid guidewires shown at 69a and 69b. FIG. 8 particularly shows the configuration of the end portion of one of the trays, showing means for retaining the members 66 and 67 in place so as to lock the pads 70 against the papers within the trays. In order to outwardly position the members 60 and 61, the members 66 and 67 are moved downwardly out of the notches 72 and 73 formed in the end of the plate 12. When the rods are below and out of the notches, they can be manipulated to pivot the plates 60 and 61 so as to permit more paper to be loaded into the trays 12.

Referring next to FIG. 9, there is shown more particularly the aligning or jogging mechanism 21 which is pivoted at 75 to the frame and is pulled to the left of FIG. 9 by a solenoid-actuated bar mechanism 76. The mechanism 21 moves in a cut-out shown at 77 formed within the cabinet or frame 11. Also shown in this figure is the position of the punch for providing a fastening element, such as a staple, into the set of papers accumulated within the bin 19. The bottom part of the stapling mechanism is particularly shown in this figure and is positioned in back of a cut-out 78 formed within the frame 11. The top portion of the stapling mechanism is better seen in FIG. 2 and is actuated by a hammer shown at 79 and a solenoid arrangement shown at 80. On actuation of the solenoid 80, the hammer 79 will move toward the top portion of the stapler 22 and cause a staple to be inserted within the set of papers held in the bin 19.

FIG. 10 illustrates the set of papers, shown at 81, havin g a staple 82 inserted therein.

Referring now to FIG. 11, there is shown a block diagram of a control system for operating the collating machine according to this invention. The basic cycle of the collating machine comprises the following four functions: raising and lowering the carriage 32, jogging the collated set of papers, stapling by the use of the member 21, and dropping the finished group into the proper stack 1n the basket 14 by opening plate 20.

The carriage 32 is held up by a continuous duty solenoid 40. To feed one page from each of the shelves, voltage to the solenoid 40 is turned off for a predetermined period of time. This allows the carriage to drop and permit the rollers 30 to make contact with the papers. After a predetermined interval has elapsed, the voltage is restored to the carriage solenoid and the carriage is raised. The drive motor runs continuously throughout the cycle. As constructed, the carriage falls freely until the drivewheels hit the paper which is loaded onto the trays or shelves 12. This allows for the changing height of the stacks as more collated sets are run off.

The jog mechanism 21 is activated by means of its solenoid 76 for a predetermined period of time after the carriage 32 is raised, thereby allowing sufficient time for the set of papers to collect in the bin or stapling assembly. The stapling occurs immediately after jogging. The stapler is driven by a. solenoid 80. After the stapling occurs, the jog solenoid 76 is deactivated.

To drop the stapled set of papers out of the bin 19, the solenoid 26 pulls back the plate 20 on which the collated set of papers is resting. This occurs immediately after stapling. The plate 20 is held back for a predetermined interval, that is, until the carriage is again raised after running off another group. The collated group drops from the machine, hits a guide plate (FIG. 3) and slides into the basket 14. If the proper number of pages is not fed from the trays 12, a solenoid 48 is actuated and places the reject plate 46 in the path of the set of papers as it falls from the machine. These papers will then fall into the reject basket 59.

For the operation of the basic functions referred to above, reference should again be had to FIG. 11 in conjunction with FIG. 12. In the block diagram of FIG. 11, silicon controlled rectifier triggering circuits are shown at 105. These circuits are schematically shown in FIG. 12. The controlled triggering circuits of FIG. 12 allow pulses, generated by timing circuits which will be described at a later time, to control the alternating current provided to the various solenoids, as well as to the motor.

The circuit of FIG. 12 comprises SORs 108 and 109 driven by a transistor 107. This transistor functions as a current amplifier and is responsive to a triggering waveform shown at the input. The transistor delivers a current pulse to trigger SCR 108, which causes it to conduct during the positive half-cycle of the AC. When SCR 108 conducts current through resistor 110, it causes a potential to appear across the resistor 110. This charges a capacitor 111 through resistor 112, triggering SCR 109 and turning it on. Thus, the SCR 109 conducts during the negative half of the AC cycle. A diode 113 prevents the capacitor 111 from discharging through resistor 112. A diode 114 clamps one side of the capacitor 111 at SCR 109 cathode potential during the negative half of the cycle. This allows proper biasing of the trigger of SCR 109, permitting it to conduct. Capacitor 111 produces a unity power factor in the AC line, putting the current in phase with the voltage.

Referring again to FIG. 11, signals for timing the machines basic functions are derived from the 1l5-volt AC 60-cycle input signal in conjunction with a transistor shown at 120. The transistor provides a positive.

Wave form at its emitter which is then fed into a NOR gate shown at 121, the output of which is a square wave of the same period and pulse duration. The square wave triggers a flip-flop G, the first of a series of seven cascaded symmetrically triggered JK flip-flops (Texas Instruments, Inc. nomenclature) which act as frequency dividers. =Each succeeding flip-flop doubles the period and pulse duration of the signal provided from the prior flip-flop in the chain. Each flip-flop has a secondary output which yields the inverse of the primary output. For example, flip-flop A has a primary output A and a secondary output A. Each flip-flop also has a preset input. Applying a positive potential to this input sets the primary output in a zero binary state and the secondary output in a one binary state. As long as the preset input has a positive voltage applied, the flip-flops will stay in their preset state regardless of triggering of other inputs. This allows the flip-flops to be preset at any time during the cycle.

The four basic pulses, carriage, jog or align,

staple and drop, are obtained by combining primary and secondary outputs from the various flip-flops A-G. To control carriage solenoid 40, a signal is obtained by feeding the primary outputs of flip-flops A and B to a NOR gate 130 which inverts the signal. The output of NOR gate 130 is inverted by NOR gate 131 and fed to NOR gate 132. NOR gate 132 inverts the signal and drives a butter amplifier shown at 133 which provides the required output power to drive the SCR 105 triggering circuit. When a positive voltage is applied to the SCR triggering circuit 105, current is allowed to flow in the carriage solenoid 40, thus lifting the carriage 32. As shown, there is also fed to NOR gate 132 a load signal, which is a positive signal to cause the carriage to be raised and held up as long as the voltage is applied. This permits the trays to be loaded when desired. To generate the jog or align pulse to actuate the solenoid 76, the primary output of flip-flop B and the secondary outputs of flip-flops A and C are coupled to a NOR chain comprising NOR circuits 140-143, respectively. Only when all three waveforms from flip-flops A, B and C are positive will there be an output from the logic circuit to cause the jog solenoid to operate. The jog signal is applied from the NOR gate 143 through a buffer amplifier 144 to control the SCR circuit 103.

In order to generate the staple pulse, there are provided NOR gates 150153 which are responsive to signals provided from A, B and C flip-flops. Signals from NOR circuit 153 are fed to a butter amplifier 145 and then to the SCR 102. To generate the drop pulse to control the door or plate 20, there is provided a flip-flop H, also of the JK type, which is triggered by a NOR gate 160. An important characteristic of the JK flip-flop is that it is triggered by the trailing edge of a pulse. Only a sudden drop from a positive voltage to a lower voltage will trigger the JK flip-flop. A NOR gate shown at 161 inverts the staple pulse and then NOR gate 160 again inverts it. Thus, the staple pulse appears on the symmetrical trigger input of flip-flop H. The trailing edge of the staples pulse triggers flip-flop H into the binary state and, thus, puts a binary one on the primary output and a binary zero on the secondary output of flip-flop H. The secondary output of flipfiop H is fed to a butter amplifier 162 which inverts the signal on its input to trigger the SCR cricuit 104. The flip-flop H remains in its binary state until the trailing edge of the carriage pulse (which has been twice inverted, like the staple pulse) triggers it into the other binary state (that in which the primary output has a binary zero and the secondary output has a binary one). Inversion by the butter 162 of the positive output of the secondary output of flip-flop H causes a low voltage (or binary zero) to appear on the input of the SCR triggering circuit. When this occurs, current ceases to flow in the drop solenoid. The load signal in the upper left-hand portion of the drawing is fed to the preset input of flip-flop H. Thus, when loading the machine, no current can flow through the drop solenoid. This also assures that the flip-flop H is in the proper binary state when the machine first starts its processing. Waveforms carriage and staple are obtained from the outputs of NOR gates and 152, respectively.

As mentioned with respect to FIG. 3, there is provided a photocell shown at 53 for intercepting a beam of light 52 transmitted from the light source 51. If all the pages reach the stapling assembly, the light beam is not broken for a sufficient period to prevent the photocell from being substantially continuously energized. This causes the photocell to place a positive voltage (a binary one) on the input of NOR gate 170. The output of NOR gate 143 is fed to the other input of NOR gate 170. The output of NOR gate 143 is the inverse of the jog waveform which keeps a binary one on NOR gate until jogging occurs. If a page is caught in the guide chute on the guide rod, the light beam is broken and a binary zero is fed to one input of NOR gate 170. When jogging occurs, a waveform E goes to a binary Zero. The presence of a binary zero on both inputs of NOR gate 170 causes a binary one to appear at its output. This output is fed to NOR gate 171, causing its output to change from a binary one to a binary zero. This change in voltage triggers the flipflop L into the binary state and sets its secondary output at a binary one. This sets all other flip-flops in their preset state, stopping the cycle, raising the carriage 32 and turning oil? the drive motor 36.

As mentioned previously in the description of FIG. 3, there are also provided wire switches 56 for determining whether or not any of the stacks of paper held in the trays has been depleted. When the pages are inserted in each tray, they raise and electrically insulate a piano wire from the shelf. A DC voltage is applied to point of resistor 181. If pages are in all of the eight trays, point 182 is not grounded and assumes the voltage at point 180. To permit collating of less than the total number of pages, that is, one for each tray, bypass switches 184 are placed in series with the piano wire switches. The operator manually closes the switches for the trays which contain the pages and opens switches for the trays which do not contain pages. Thus, only piano wire switches of the shelves in use are in the electrical circuit. When a shelf becomes empty of pages, the piano wire switch 56 grounds point 182 as the last page is being fed out of the shelf, placing a binary zero on one input of NOR gate 190. A signal from flip-flop A is also fed through NOR gate 191 to NOR gate 190. When the flip-flop A goes to a binary zero, the output of NOR gate goes to a binary one. NOR gate 192 inverts this signal to a binary zero, triggering flipflop I. Flip-flop I assumes the binary state that places a binary one on its secondary output. A buffer amplifier 193 inverts this signal, placing a binary zero on the input of SCR switching circuit 100 and turns off the drive motor. The primary output of flip-flop I places a binary zero on one input of NOR gate 200'. Signals A and (mg e are fed to the inputs of NOR gate 201. When both of these signals are at binary zero, the output of NOR gate 201 assumes a binary one. This is inverted by NOR gate 202, placing a binary zero on the second input of NOR gate 200. The presence of a binary zero on both inputs of NOR gate 200 causes a binary one at its output which is fed to NOR gate 171, causing flip-flop L to preset all other flip-flops, stopping the cycle.

As noted with reference to the description of FIG. 6, the system includes a page-miss detector circuit which provides an indication as to whether or not a page has been dispensed from a particular tray. As the page is fed from the tray, the forward edge of the page closes the microswitches shown at 58. Thus, if a page is fed from each shelf, a binary one is applied to NOR gate 210, causing the input of flip-flop K to change from a binary one to a binary zero and triggers the flip-flop into the primary state, putting a binary one on one input of NOR gate 211. When stapling occurs, the staple waveform goes binary Zero on the input of the buffer amplifier 213. The

amplifier 213 puts a binary one on SCR triggering circuit 101 and current flows in the miss solenoid. Pip-flop J is reset by the trailing edge of the drop pulse and current ceases to How in the miss solenoid. To permit collating of less than the total number of pages, that is, one for each tray, each microswitch is paralleled by a manual bypass switch shown at 214. The operator must close the switches for the trays which do not have pages and must open the switches for the trays which have pages. Since these bypass switches are positioned opposite those of the empty stack, selector bypass switches, one single-pole doublethrow switch for each tray, will perform both functions.

The schematic diagram of FIG. 11, illustrates a case in which no pages are held within the last four trays. In order to load the trays with pages, the operator presses the load switch, shown at 220, which places a binary one on the input of NOR gate 171, causing a binary zero to appear at its output. This triggers fiip-fiop L into the binary state that puts a binary one on the secondary output. This output is fed to the preset input of all other flip-flops, except flip-flop I, and to one input of NOR gate 132. This initializes all flip-flops except flip-flop I and causes the carriage 32 to be raised by actuating the solenoid 40. The output of NOR gate 171 is fed through NOR gate 221 to the preset input of flip-flop 1. Thus, when the output of NOR gate 171 triggers flipfiop L, a positive pulse of short duration appears on the preset input of flip-flop I, presetting it. This permits the drive motor to be started before processing begins. After loading the trays the operator sets the bypass switches in proper position and pushes the motor start button 223, causing flip-flop I to be triggered and the motor 36 starts. The operator then pushes the process button 224 which triggers flip-flop L, removing the binary one from its secondary output. The output of NOR gate 121 then triggers fiip-fiop G and the cycle begins. The cycle may be stopped at any time by pressing the load button 220.

Reference should now be had to FIG. 13, which shows the various signal waveforms described with respect to FIG. 11. The outputs of the various flip-flops A-D are shown, as well as the signals provided to the carriage, jog, staple and drop solenoids.

It will thus be seen that the objects set forth above, among those made apparent from the preceding description, are efiiciently attained and since certain changes may be made in the above construction without departing from the spirit and scope of the invention, it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.

It is also to be understood that the following claims are intended'to cover all the generic and specific features of the invention herein described, and all statements of the scope of the invention which, as a matter of language, might be said to fall therebetween.

What is claimed is:

1. A collating machine, comprising a cabinet, 3. plurality of vertically arranged paper holding trays supported in the cabinet, a bin positioned below said trays for receiving the papers so as to form a set of papers, and

ejecting means 'for dispensing the papers into said bin such that they form a set in a predetermined order, said ejecting means comprising a carriage supporting a plurality of rollers cooperating to dispense paper held in said trays, and lifting means for raising said carriage to lift said rollers above said paper held in said trays and guide means coupled to each tray for guiding said papers into said bin.

2. A collating machine according to claim 1, in which said guide means comprises a plurality of elongated rods coupled to each tray.

3. A collating machine according to claim 1 including a motor having a first drive shaft for rotating said rollers.

4. A collating machine according to claim 3, wherein said drive shaft is coupled to drive said rollers through a second drive shaft coupled through a slip coupling to said first drive shaft.

5. A collating machine according to claim 1, wherein said bin has an opening through which sets of papers pass on their way toward being collected and in which door means are provided adjacent said opening for retaining said sets of papers in said bin until a predetermined time.

6. A collating machine according to claim 1, in which means are provided for fastening together the papers held in said bin.

7. A collating machine according to claim 1, in which means are provided for sensing if a paper has become stuck in said guide means.

8. A collating machine according to claim 1, in which feeler means and pivotal chute means are provided for rejecting the set of papers collected in the bin in the event a page is missing from the set of papers.

9. A collating machine according to claim 1, in which means are provided for aligning the pages of the set while they are held in the bin.

10. A collating machine comprising a plurality of trays for holding papers to be arranged in a set, means for dispensing and guiding the papers held by the trays into a collector, having an opening therein, means for fastening the set of papers together while they are held in the col- .lector and door means positioned adjacent said opening in said collector for releasing the set of papers from said collector so that said set may pass into a-collecting basket.

11. A collating machine, comprising a cabinet, a plurality of vertically arranged paper holding trays supported in the cabinet, a bin positioned below said trays for receiving papers so as to form a set of said papers, roller drive means for dispensing the papers into said bin such that they form a set in a predetermined order wherein said roller means engages the top sheet of paper stacked in each tray, guide means coupled to each tray for guiding said papers into said bin, feeler means positioned on each said tray for sensing dispensed papers and pivotal chute means positioned below said bin and responsive to said feeler means for rejecting the set of papers collected in said bin in the event a page is missing from the set of papers.

References Cited UNITED STATES PATENTS 2,624,571 l/1953 Dixon et a1. 27058 3,108,797 10/ 1963 Mestre 27058 3,273,882 9/1966 Pearson 27058 EUGENE R. CAPOZIO, Primary Examiner P. V. WILLIAMS, Assistant Examiner US. Cl. X.R. 27053 

